Asphalt-based dust control formulations

ABSTRACT

This disclosure describes formulations and methods for dust control, for example, coal topping, a term which refers to the application of liquid products to the top of coal loads, such as those in open topped coal hopper railcars as commonly used today to transport coal. Disclosed herein are asphalt-based emulsion formulations that accomplish dust control during industrial operations in which dust handling is required.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. patent application Ser. No.15/421,550, filed Feb. 1, 2017 which claims benefit of U.S. ProvisionalApplication 62/289,732, filed Feb. 1, 2016, the contents of which areincorporated herein by reference.

TECHNICAL FIELD

The present invention relates to dust control compositions. Morespecifically, the invention is directed to dust-inhibiting concentratesand other solutions containing asphalt emulsions. This disclosuredescribes formulations and methods for dust control, for example, coaltopping, a term which refers to the application of liquid products tothe top of coal loads, such as those in open topped coal hopper railcarsas commonly used today to transport coal. Disclosed herein areasphalt-based emulsion formulations that accomplish dust control duringindustrial operations in which dust handling is required.

BACKGROUND

Many industrial operations create fugitive dust. Because it can beairborne, fugitive dust is an environmental and a health hazard and insome cases, even a fire hazard. Airborne dust can also mean loss ofusable material. Also, the airborne particles are highly pervasive andcan enter the nose, lungs, eyes and even the pores of the skin.Industrial operations requiring dust prevention include dumping ofmaterial, transportation, transfer point operation, stockpiling,storage, reclaiming, conveyoring, shearing, continuous mining, crushing,screening and sifting, drying, packaging and filling.

All types of dust including soil particles, industrial products,by-products and waste, coal dust, road dust and many others presenthazards. Some examples of particulate materials that produce dustinclude for example, ground limestone (10 to 1000 μm); fly ash (10 to200 μm); coal dust (1 to 100 μm); cement dust (3 to 100 μm); carbonblack (0.01 to 0.3 μm); and pulverized coal (3 to 500 μm).

For example, the high speed transportation of coal by rail may causeloss of fine coal particles. In fact, coal trains are known as “blacksnakes.” The name aptly describes the miles of uncovered rail carsbearing the black cargo as they slither along the tracks. During thejourney from coal mines to their final destinations, coal trains shedplumes of coal dust from the tops of the train cars. As the dust spewsfrom the rail cars, it fills the surrounding air with harmful substancessuch mercury, lead, cadmium, arsenic, manganese, beryllium, andchromium. When the dust settles, these substances are deposited in soiland water, harming plant, animal, and marine life.

Both train vibration and airspeed (from wind or due to the speed oftrain) can lift particles from exposed coal making them airborne anddepositing them along the right-of-way and transporting them by windconsiderable distances. In addition to environmental hazards, healthhazards and product loss, coal dust lost during transportation can alsodamage transportation infrastructure. Environmental consequences fromcoal dust are also rooted in railroad safety concerns. Coal dustaccumulation in the ballast can destabilize the tracks and contribute toderailments. Derailments impact the environment because the overturnedtrain can spill locomotive fuel and dump thousands of pounds of coal andcoal dust, resulting in soil and water contamination.

Fugitive dust problem avails itself to two solutions: (1) lowered dustcreation; and (2) dust control through prevention, suppression, capture,or removal.

This invention relates to the second solution, that is, dust control.Dust control can be approached in four ways: (1) using wet systems thatuse water sprays to prevent dust or capture airborne dust; (2) usingenclosures to contain dust; (3) using ventilation systems/exhaustsystems to remove dust; (4) using a combination of these techniques.More specifically, this invention relates to novel asphalt-basedemulsion formulations in wet spray systems that can assist in dustcontrol.

Halide brines, comprising one or more dissolved or suspended salts inwater, usually halide salts, especially chloride salts, particularlycalcium chloride, magnesium chloride and other alkali metal and alkalineearth metal salts, are used extensively for inhibiting dust on a varietyof surfaces including such uses as dust control of roadways, pavedareas, bridges and the like as well as for inhibiting dust on surfacesof bulk materials, such as coal, coke, limestone and minerals. They arealso used for dust control, especially during dry weather during thehandling and transportation of dust-producing bulk materials, such ascoal, coke and limestone.

Aqueous solutions of these halides are known to corrode metals and causescaling or surface damage to concrete. For example, heavy use of roaddeicers can result in serious damage to steel, particularly autos andother vehicles, as well as rapid deterioration of steel reinforcing rodsin poured concrete roadways and bridges. The halides used for dustcontrol of bulk materials such as coal or other minerals often causecorrosive deterioration of the materials-handling equipment, rail carsand other container carriers.

In accordance with the present invention, it has been found that in oneembodiment, a formulation comprising asphalt emulsions resistsabsorption into pores of coal and other mineral surfaces, includingsoil, so that after drying into a continuous or discontinuous film, theasphalt emulsion will provide later dust control, as well as exhibitingdust control and anti-corrosion properties upon later wetting withwater.

The composition of the present invention addresses the above discussedproblems of dust generation. The emulsion of the present inventioncomprising asphalt-based emulsion can be added to a water based spraysystem that can then be used for spraying on to the particulatematerial, for example, coal, to control the dust.

SUMMARY

The following presents a simplified summary of one or more aspects inorder to provide a basic understanding of such aspects. This summary isnot an extensive overview of all contemplated aspects, and is in-tendedto neither identify key or critical elements of all aspects nordelineate the scope of any or all aspects. Its sole purpose is topresent some concepts of one or more aspects in a simplified form as aprelude to the more detailed description that is presented later.

More specifically, the present invention provides a dust controlformulation (“DCF”) that includes a dust reducing or control additive(“DCA”). Generally, the DCF includes a sufficient amount of the dustcontrol additive so that when the DCF is tested as described in thisspecification, it generates a lower quantity of airborne dust than DCFwould produce if it did not contain the dust control additive.

Disclosed herein are embodiments of a low-dust DCF that comprises waterand dust reducing additive, which is an asphalt emulsion comprisingasphalt, preferably, an asphalt blend. The DCA can be pre-mixed into thewet DCF prior to application. Generally, the dust reducing additivereduces the quantity of airborne dust particles having a size of lessthan or equal to 10 microns to less than 50% of the quantity that wouldbe generated without the additive. In certain embodiments, the quantityof airborne dust particles is reduced by at least 75% compared to amixture without the additive. It is desirable that the dust controladditive serve to suppress the formation of airborne particles withoutsignificantly interfering with the desired characteristics of the DCF.The present invention in fact discloses a DCF that has a synergisticcombination of improved dust control property, improved waterresistance, and improved adhesive property.

In one embodiment, the DCF can include a conventional filler materialand a binder material, such as a resin. The DCF can also include asurfactant, which may or may not serve to suppress airborne dustformation, and optionally a thickening agent. Prior to hardening, theDCF preferably includes a sufficient amount of water to form a mud-likespreadable material which can be applied to the substrate surface. Insome embodiments, the DCF can comprise the dust control additiveemulsion and can have a contact angle of about 90 to about 130 degrees,a pH below 12, and a Cobb value of about 1.0 to about 1000 grams persquare meter.

In some embodiments, the DCF can further comprise a rheology modifier, abinder, a thickener, and filler. In some embodiments, the DCF canfurther comprise calcium carbonate, or cristobalite, or amicro-roughened filler, or gypsum, or mica, or clay, or thickener, or alatex binder, or talc, or perlite, or expanded perlite, or combinationsthereof. In some embodiments, the DCF can comprise the asphalt emulsionwhich can comprise water, low CVS emulsifier, and a first defoamer. Thelow CVS emulsifier comprises of water, optionally a disper-sant such astetrasodium pyrophosphate, optionally an emulsifier fatty acid solutionsuch as Vinsol® (abietic acid), a second defoamer, a base and asuspension agent such as clay slurry.

In some embodiments, the DCF reduces reduction of peak airborne dustproduction from about 10% to about 98% compared to the commerciallyavailable DCF dust control additive.

In some embodiments, the DCF can have a pH below 9. In some embodiments,the DCF can have a contact angle of about 60 to about 130 degrees. Insome embodiments, the DCF can be generally hydrophobic and can have acontact angle of about 110 to about 130 degrees. In some embodiments,the DCF can have a Cobb value of about 1.0 to about 1000 (g)/m2. In someembodiments, the DCF can have a Cobb value of about 65 (g)/m2.

In some embodiments, the DCF can further comprise a rheology modifier, abinder, a thickener, and a filler. In some embodiments, the DCF canfurther comprise calcium carbonate, or cristobalite, or amicro-roughened filler, or gypsum, or mica, or clay, or thickener, or alatex binder, or talc, or perlite, or expanded perlite, or combinationsthereof.

In some embodiments, the DCF can comprise asphalt blend, water, clay,phosphoric acid, preservative, and a filler such as wollastonite.

In one embodiment, the present invention relates to a method forcontrolling dust on a surface of a bulk material, comprising:

(I) preparing a dust control formulation (DCF) comprising a dustreduction additive (DRA) emulsion comprising asphalt; and

(II) applying said dust control formulation to said surface of said bulkmaterial in an amount effective for dust control.

In another embodiment, the present invention relates to the methoddescribed above, wherein said dust control formulation is applied bysprinkling, and/or a spray nozzle.

In another embodiment, the present invention relates to the methodsdescribed above, wherein said dust control formulation further comprisesa first water.

In yet another embodiment, the present invention relates to the methodsdescribed above, wherein said DRA emulsion comprising asphalt furthercomprises:

(A) at least one defoamer; and

(B) at least one emulsifier.

In one embodiment, the present invention relates to the methodsdescribed above, wherein said asphalt in said DRA is from about 30% toabout 70% by weight of the DRA.

In another embodiment, the present invention relates to the methodsdescribed above, wherein said asphalt in said DRA is from about 30% toabout 70% by weight of the DRA; wherein said at least one defoamer insaid DRA is from about 0.00005% to about 0.00030% by weight of the DRA;and wherein said at least one emulsifier in said DRA is from about 30%to about 70% by weight of the DRA.

In yet another embodiment, the present invention relates to the methodsdescribed above, wherein said at least emulsifier is a low-fatty acidemulsifier; comprising water; a fatty acid solution; a base; andoptionally comprising a dispersant; optionally comprising a stabilizer;optionally comprising a defoamer; and optionally comprising a suspensionagent.

In one embodiment, the present invention relates to the methodsdescribed above, wherein said suspension agent is a clay slurry.

In another embodiment, the present invention relates to the methodsdescribed above, wherein said asphalt in said DRA is an asphalt blend.

In yet another embodiment, the present invention relates to the methodsdescribed above, wherein said DCF further comprises a binder; apreservative; a rheology modifier; and/or a surfactant.

In one embodiment, the present invention relates to the methodsdescribed above, wherein said dust-reduction additive emulsion furthercomprises a second water; a base; and a dispersant.

In another embodiment, the present invention relates to the methodsdescribed above, wherein the weight of said dust reduction additiveemulsion is in the range of from about 0.01% to about 20% by weight ofsaid dust control formulation.

In a further embodiment, this invention relates to methods describedpreviously, wherein the weight of said dust reduction additive emulsionis in the range of from about 0.1% to about 10% by weight of said dustcontrol formulation.

In one embodiment, this invention relates to methods describedpreviously, wherein said dust control formulation is applied to thesurface of said bulk material at the rate of from about 0.001 to about5.0 gallon per square yard for controlling dust.

In another embodiment, this invention relates to methods describedpreviously, wherein said bulk material is coal, limestone, fly ash,cement, carbon black, coke, or mineral material.

In yet another embodiment, this invention relates to methods describedpreviously, wherein said bulk material is coal, and said dust controlformulation is applied the top of said coal load in an open-topped,coal-hopper railcar, used for transporting coal.

Finally, this invention also relates to a concentrated dust controlformulation, suitable for dust control upon dilution with waterconsisting essentially of water and about 5-80% weight of dust controladditive emulsion comprising asphalt.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed aspects will hereinafter be described in conjunction withthe appended Drawings, provided to illustrate and not to limit thedisclosed aspects, wherein like designations denote the elements.

FIGS. 1 and 2 illustrate a “cake” formed as a result of asphalt emulsionbased DCF spraying on the particulate coal.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The terms “approximately”, “about”, and “substantially” as used hereinrepresent an amount close to the stated amount that still performs adesired function or achieves a desired result. For example, the terms“approximately”, “about”, and “substantially” may refer to an amountthat is within less than 10% of, within less than 5% of, within lessthan 1% of, within less than 0.1% of, and within less than 0.01% of thestated amount.

Typical surfaces that require treatment for exposure to dust-yieldingconditions are mineral, e.g., coal mines, coal, coke or limestone beingtransported by rail car, roadways, pavements, paved and unpaved openareas such as stock yards, bridges and the like. Coal, coke, limestoneand other minerals may also produce dust that must be contained so as tolimit pollution of the environment. Automobiles, metal rods used inconstruction of roads and bridges and the steel and metal componentsassociated with the railways and other materials-handling equipmentbenefit from the corrosion-inhibiting feature of asphalt emulsion duringtreatments for dust control.

In accordance with a preferred embodiment of the methods describedherein, the solution of asphalt emulsion in water is used to bind dustparticles to larger particles, particularly on mineral, e.g., coal, minefloors and on coal during transport via uncovered rail cars. On mineralmine floors and as a surface covering for coal and other dust-producingminerals being transported in uncovered rail cars, the asphalt emulsionpreferably has a concentration of about 4-8 wt. percent in water % tobind smaller mineral particles to larger mineral particles. The asphaltemulsion coating resists absorption of the solution into the pores ofthe larger mineral particles and resists water evaporation to maintainthe binding capability of the asphalt emulsion for continued binding ofsmaller mineral particles to larger mineral particles, even duringmovement and settling during transport.

If repeated applications of the asphalt emulsion solution are needed,such as on a roadway surface during construction, the asphalt emulsionconcentration increases with each application to maintain the soilsurface damp for an unexpectedly long period of time, e.g., about fourtimes or more as long as using water only. The asphalt emulsioncompositions described herein can be applied as asphalt emulsion inwater. Alternatively, the composition can be provided as a slurrycontaining asphalt emulsion.

In the method of dust control, the DCF is applied to a surface of thematerial requiring dust control. One preferred rate of application isfrom about 0.001 to 5.0 gallons of admixture per square yard of surfacetreated. Rates vary according to the surface receiving the application.With unpaved roads, for example, the rate of application can be adjustedwithin a preferred range of 0.1 to 1.5 gallon of blend to one squareyard of road. Treatment rates of application for other surfaces areknown in the art.

The admixture can be applied to the surfaces of roads, bridges or bulksubstances carried in open containers by any of several methods known inthe art. One preferred method is sprinkling of the admixture solutionover the surface requiring freeze conditioning or dust control. Anotherpreferred method is spraying the admixture by nozzles, preferablypressurized nozzles, so that the mechanical action of the spray providescomplete coverage of the admixture into unpaved road surfaces, coal,coke, limestone, and the like. Other known methods can be used to applythe admixture.

General Embodiments

There are several constraints that apply to a dust control formulationsuch as coal-topper formulations. A tensile strength high enough toresist cracking when subjected to shocks and wind during transport ispreferred. For the same reason, greater flexibility is also preferred.Due to the cost of water, a low water requirement is preferred. Arelatively higher depth of penetration, which is directly related to theviscosity of the coal topper formulation, is preferred to bind as muchcoal mass at the surface as possible. Viscosity is related to theability of the polymer fluid to penetrate the surface of the subjectmedia. In particular coal particulates, which have different wettingproperties than normal soil or rock particulate, will reject fluid withexcessive viscosity while accepting lower viscosity fluid. It isspeculated that a hydrophobic mechanism may play a part, possible aresult of the hydrocarbon interaction with the coal topper. In addition,the coal topper formulation must not inhibit the ability to unload orburn the coal. A coal topper should not excessively corrode thetransport equipment such as the railcars or loading/unloading equipment.

The dust control formulations of the present invention serve all of theabove advantages. Embodiments of the present disclosure provide a dustcontrol additive (“DCA”) comprising asphalt emulsion. In anotherembodiment, the present invention relates to the process of preparingsuch dust control additive emulsions. Dust control additive refers toany ingredient capable of preventing, minimizing, suppressing, reducing,or inhibiting the formation of particles capable of becoming airborne.The expressions “airborne particles” or “airborne dust particles” referto fine particles generated during the many industrial and/or otherprocess operations such as dumping of material, transportation, transferpoint operation, stockpiling, storage, reclaiming, conveyoring,shearing, continuous mining, crushing, screening and sifting, drying,packaging, filling, sanding and abrading While the disclosure infradescribes the DCA of the present invention in the context of coaltopping, the DCA emulsion can also be used with other particulatematerials where airborne particles are generated.

The present invention also relates to dust control formulationscomprising the dust control additive and methods for preparing such dustcontrol formulations. By “dust control formulation” (DCF) is meant aformulation such as a spray comprising DCA emulsion which helps incontrol of airborne particles. According to the present invention, thereare provided dust control formulations suitable for spraying andapplying to particulate materials requiring dust control. Thecompositions of the present invention include a dust control additivecombined with other ingredients to form an aqueous system, or anon-aqueous system including fillers, binders, and/or thickeners to forma DCF.

In addition to providing a dust control property, the DCF of the presentinvention may also be hydrophobic, and thus, water-resistant. Further,the embodiments of the present invention also provide adhesiveproperties to particulate material to which it is added.

The DCF may be used to create a low-dust, water resistant barrier overthe materials on which it is sprayed thereby reducing the dust generatedduring process and preventing moisture from passing through thematerial. Further, the disclosed DCF formed from an asphalt emulsion canassist with adhesion.

The DCF can be used on various materials such as ground limestone (10 to1000 μm); fly ash (10 to 200 μm); coal dust (1 to 100 μm); cement dust(3 to 100 μm); carbon black (0.01 to 0.3 μm); and pulverized coal (3 to500 μm).

In accordance with a characterizing feature of the present invention,the DCF comprises the DCA emulsion which minimizes the quantity ofairborne particles generated, for example, during operation ofindustrial processes. The DCA generally comprises less than 20% of theDCF wet weight. More preferably, the dust control additive comprisesbetween about 0.1% and about 10% of the dust control formulation by wetweight percent and, most preferably, between about 1.5% and about 6%. Inone embodiment, the DCA is selected from any one of the following weightpercentages:

0.1, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,and 20

The weight percentage of DCA emulsion in the DCF can be any numberwithin the range defined by any two numbers above, including theendpoints. The dust control additive of the present invention isdescribed in detail infra.

Many ingredients have been found to effectively reduce the quantity ofairborne particles generated, including oils such as animal, vegetable,and mineral oils (saturated and unsaturated), and oils derived frompetroleum, pitch, natural and synthetic asphalts, paraffins, solventswhich evaporate slower than water, terpenes, glycols, surfactants, andmixtures thereof. However, the asphalt emulsion based DCA emulsion ofthe present invention unlocks the synergistic effect of the threedesired properties in the DCF, namely, dust control property, waterresistance, and adhesion. dust control additive may cause the dustparticles to agglomerate or stick together, thereby forming large heavyparticles which tend not to become or remain airborne.

Dust Control Additive Definitions

For the purposes of this invention, an “asphalt blend” is a blend ofvarious asphalt fractions from distillation of crude oil.

Asphalt Blend Compositions

Any suitable asphalt or asphalt cement may be employed for producing themodified asphalt blend compositions of the invention. For example,industrial asphalts used for coatings, sealants, roofing materials,adhesives, and other applications may be used. Paving grade asphaltcompositions, however, are employed in the preferred embodiment of theinvention. Asphalt compositions may be derived, as indicated, from anywell-known bituminous or asphaltic substance obtained from naturalsources or derived from a number of sources such as petroleum, shaleoil, coal tar, and the like, as well as mixtures of two or more of suchmaterials. Typical of such asphalts are the straight run asphaltsderived from the atmospheric, steam and/or vacuum distillation of crudeoils, or those asphalts derived from solvent precipitation treatments ofraw lubricating oils and their fractions. Also included are the thermalor “cracked” asphalts which are separated as cracker bottom residuesfrom refinery cracking operations and the asphalts produced asbyproducts in hydrorefining operations. In one embodiment, the asphaltis the vacuum tower bottoms that is produced during the refining ofsynthetic or petroleum crude oils. For example, in one embodiment, anysuitable paving grade asphalt may be employed for the compositions ofthe invention. Such paving grade asphalt compositions are often referredto as viscosity, penetration graded, or performance graded (PG) asphaltshaving penetrations up to 400 as measured by ASTM method D5.

In some embodiments, the asphalts are the performance graded asphaltssuch as PG 46-40, PG 46-34, PG 46-28, PG 52-40, PG 52-34, PG 52-28, PG52-22, PG 58-40, PG 58-34, PG 58-28, PG 58-22, PG 64-40, PG 64-34, PG64-28, PG 64-22, PG 70-40, PG 70-34, PG 70-28, PG 70-22, PG 76-40, PG76-34, PG 76-28, PG 76-22, PG 82-34, PG 82-28, or PG 82-22.

The PG in the title refers to Performance Graded, the first numericdesignation refers to the binder's high temperature rutting ordeformation resistance temperature range limit, and the last numericdesignation refers to the binder's low temperature thermal crackingresistance temperature limit. Complete specification requirements areoutlined in specifications under AASHTO MP-1-93 Performance GradedAsphalt Binder Specification. AASHTO is the designation for the AmericanAssociation of State and Highway Transportation Officials.

Dust Control Additive Asphalt Emulsion

Exemplary emulsion comprising asphalt emulsion for use in, for example,as a dust control additive (and for water-resistance) in a DCF are nowdescribed in greater detail, as follows.

In one embodiment, the asphalt emulsion comprises an asphalt blend, adefoamer, and a low fatty acid emulsifier. The components are mixedusing standard procedures to make the asphalt emulsion.

The asphalt blend is as described previously. The asphalt content in theasphalt emulsion (the DCA) is from about 30% to about 70% of the totalweight of the asphalt emulsion. Stated another way, the asphalt contentin the asphalt emulsion DCA is 30, 31, 32, 33, 34, 35, 36, 37, 38, 39,40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57,58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or 70 percent of theweight of the emulsion or the weight of the emulsion from a rangedefined by any two numbers and including the two numbers above.

The weight of the defoamer is from about 0.00005 to 0.00030% of thetotal weight of the asphalt emulsion. Stated another way, the defoamercontent is 0.00005, 0.00006, 0.00007. 0.00008, 0.00009, 0.00010,0.00011, 0.00012, 0.00013, 0.00014, 0.00015, 0.00016, 0.00017, 0.00018,0.00019, 0.00020, 0.00020, 0.00021, 0.00022, 0.00023, 0.00024, 0.00025,0.00026, 0.00027, 0.00028, 0.00029, or 0.00030 percent of the weight ofthe emulsion or the weight of the emulsion from a range defined by anytwo numbers and including the two numbers above.

The low fatty acid emulsifier (CVS emulsifier) is in the range of fromabout 30 to 70% of the total weight of the asphalt emulsion. Statedanother way, the CVS emulsifier in the asphalt emulsion DCA is 30, 31,32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49,50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,68, 69, or 70 percent of the weight of the emulsion or the weight of theemulsion from a range defined by any two numbers and including the twonumbers above.

In all formulations described herein, optionally, a wetting agent suchas polyethersiloxane can be added, for example in the range of from0.05% to 1%.

The Low CVS Emulsifier

The low CVS emulsifier comprises water, optionally a dispersant thatlowers the viscosity of the system such as tetrasodium pyrophosphate,optionally a stabilizer such as abietic acid (Vinsol®), optionally adefoamer, optionally a suspension agent such as clay slurry, and a basesuch as potassium hydroxide (KOH).

Preferably, the water content in the low CVS emulsifier is from 40 to80%; the dispersant is from 0.05 to 0.3%; the fatty acid solution isfrom 10-25%; the defoamer is from 0.0001 to 0.005%; and the suspensionagent such as a clay slurry in the range of 10% to 30%.

In one embodiment, the water content can be 40, 41, 42, . . . , 77, 78,79, or 80%, or a number residing within a range defined by any twonumbers inclusive of the two numbers given here. Similarly, thedispersant can be 0.05, 0.100, 0.150, 0.200, 0.250, or 0.300% or anumber defined by and inclusive of any two numbers stated herein.Similarly, the fatty acid solution is 10, 11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30% of the weight ofthe CVS emulsifier. The defoamer can be 0.00010, 0.00050, 0.00100,0.002, 0.003, 0.004, or 0.005 percent, or a number within a rangedefined by and inclusive of any two numbers herein. The clay slurrycontent is 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24,25, 26, 27, 28, 29, or 30 percent or a number within a range defined byand inclusive of any two numbers herein.

The components are mixed as a matter of standard procedure to make theCVS emulsion.

Clay Slurry

In one embodiment, clay slurry is used as a suspension, which containsfrom 80-95% water, 5-19% bentonite clay and 0.5 to 2% potassium oxalate.

In an alternative embodiment, the asphalt emulsion comprises from about45-50% water; 35-45% asphalt blend; 2-6% bentonite clay; 0.02-0.07%phosphoric acid; 0.05 to 0.2% preservative; 0.1 to 1% wollastonite; and5-12% of kaolin clay.

The clay slurry is formed as a result of using standard procedure tomake the clay slurry.

In one embodiment, both asphalt emulsions described above are diluted toabout 4% solution and then sprayed onto a coal rail car.

FIGS. 1 and 2 are photographs of the top cake formed as a result ofspraying the asphalt emulsion dust reducing additive-comprising DCF.Upon spraying, a half-inch thick cake forms on the coal surface in therailcar, which protects the cola particles from getting airborne.

In some embodiments, a dispersant and/or a surfactant may be employed inthe asphalt emulsions. Optional dispersants, include, but are notlimited to those having a sulfur or a sulfur-containing group(s) in thecompound such as sulfonic acids (R—S(═O)2-OH) and their salts, whereinthe R groups may be otherwise functionalized with hydroxyl, carboxyl orother useful bonding groups. In some embodiments, higher molecularweight sulfonic acid compounds such as lignosulfonate, lignosulfonicacid, naphthalene sulfonic acid, the sulfonate salts of these acids andderivatized or functionalized versions of these materials are used inaddition or instead. An example lignosulfonic acid salt is Polyfon® Havailable from MeadWestvaco Corporation, Charleston, S.C. Otherdispersants may be used, such as magnesium sulfate, polycarboxylatetechnology, ammonium hepta molybdate/starch combinations, non-ionicsurfactants, ionic surfactants, zwitterionic surfactants and mixturesthereof, alkyl quaternary ammonium montmorillonite clay, etc. Similarmaterials may also be used, where such materials may be compatible withand perform well with the formulation components.

In one embodiment, a dispersant and/or surfactant may comprise about0.01% to about 5.0% by weight of the asphalt emulsion formulationcomposition, preferably about 0.1% to about 2.0% by weight of theasphalt emulsion formulation composition. Other concentrations may beused.

In some embodiments, the stabilizer comprises a polymer that is capableof hydrogen bonding to the carboxylate or similar moieties at thewater/paraffin interface. Polymers that fit the hydrogen-bondingrequirement would have such groups as hydroxyl, amine, and/or thiol,amongst others, along the polymer chain. Reducing the polymer's affinityfor water (and thus, its water solubility) could be achieved byinserting hydrophobic groups such as alkyl, alkoxy silanes, or alkylhalide groups into the polymer chain. The result may be a polymer suchas ethylene-vinyl acetate-vinyl alcohol terpolymer (where the vinylacetate has been substantially hydrolyzed). The vinyl acetate contentmay be between 0% to 15%. In some embodiments, the vinyl acetate contentis between 0% and 3% of the terpolymer chain. The ethylene-vinylalcohol-vinyl acetate terpolymer may be included in the emulsion in anamount of up to about 10.0% by weight, preferably 0.1% to about 5.0% byweight of the emulsion. In some embodiments, ethylene-vinylalcohol-vinyl acetate terpolymer may be included in the emulsion in anamount of about 2% to about 3% by weight of the asphalt emulsion. Anexample ethylene-vinyl alcohol-vinyl acetate terpolymer that isavailable is the Exceval AQ4104™, available from Kuraray ChemicalCompany.

The dust control additive asphalt emulsion may include a stabilizermaterial (e.g., PVOH, ethylene-vinyl alcohol-vinyl acetate terpolymer asdescribed above). The stabilizer may be soluble in water at elevatedtemperatures similar to those disclosed with reference to PVOH (e.g.,about 60° C. up to about 95° C.), but insoluble in cold water. Theactive species in the asphalt component (e.g., montan asphalt) may bethe carboxylic acids and esters, which may comprise as much as 90% ofthe asphalt. These chemical groups may be converted into carboxylatemoieties upon hydrolysis in a high pH environment (e.g., in anenvironment including aqueous KOH). The carboxylate moieties may act asa hydrophilic portion or “head” of the molecule. The hydrophilicportions can directly interface with the surrounding aqueousenvironment, while the rest of the molecule, which may be a lipophilicportion or “tail”, may be embedded in the hydrocarbon asphalt.

In some embodiments, the asphalt emulsion comprises a base. For example,the emulsion may comprise an alkali metal hydroxide, such as potassiumhydroxide or other suitable metallic hydroxide, such as aluminum,barium, calcium, lithium, magnesium, sodium and/or zinc hydroxide. Thesematerials may serve as saponifying agents. Non-metallic bases such asderivatives of ammonia as well as amines (e.g., diethanolamine ortriethanolamine) can also be used. Combinations of the above-mentionedmaterials are also possible. If included in the asphalt emulsion,potassium hydroxide is preferably present in an amount of 0% to 1%, morepreferably about 0.1% to about 0.5% by weight of the asphalt emulsion.

The asphalt emulsion may further include other additives, includingwithout limitation additional emulsifiers and stabilizers typically usedin asphalt emulsions, flame retardants, lignocellulosic preservingagents, fungicides, insecticides, biocides, asphalts, sizing agents,fillers, binders, additional adhesives and/or catalysts. Such additivesare preferably present in minor amounts and are provided in amountswhich will not materially affect the resulting composite boardproperties. Preferably no more than 30% by weight, more preferably nomore than 10%, and most preferably no more than 5% by weight of suchadditives are present in the asphalt emulsion.

The asphalt emulsion may be prepared using any acceptable techniquesknown in the art or to be developed for formulating asphalt emulsions.

Some or all steps of the above method may be performed in open vessels.However, the homogenizer may use pressure in its application.

Advantageously in some embodiments, the emulsion, once formed, is cooledquickly. By cooling the emulsion quickly, agglomeration and coalescenceof the asphalt particles may be avoided.

In some embodiments the clay slurry and the CVS emulsifier are combinedin a pre-mix tank. In other embodiments, the clay slurry and the otherCVS emulsifier components may be combined for the first time in ahomogenizer. Then this emulsifier is combined to form asphalt emulsion,or the dust reduction additive.

Dust Control Formulation

Embodiments of the disclosed asphalt emulsion based dust controladditive emulsion can be used to form a dust control formulation (DCF).The DCF can be used to top coal-carrying railcars. It can also be usedin various industrial operations to control the dust formation, forexample, in all coal processes such as size reduction.

In one embodiment, an appropriately prepared formulation is sprayed overthe coal, which penetrates the materials and binds the particles thatcould otherwise be airborne. The DCF can also be specially formulated toserve as a cover coat on in storage facilities such as silos and binsand other containers. The DCF can be particularly useful in locationswhere there is high humidity. The weight range of asphalt emulsion inthe DCF ranges from 1% to 10% of the DCF.

The DCF can comprise a filler material. Any conventional filler materialcan be used in the present invention. Suitable fillers include calciumcarbonate (CaCO3) and calcium sulfate dihydrate (CaSO4 2H₂O commonlyreferred to as gypsum) for ready mixed type DCFs, and calcium sulfatehemihydrates (CaSO4-½H2O) for setting type DCFs. The DCF can alsoinclude one or more secondary fillers such as glass micro bubbles, mica,perlite, talc, limestone, pyrophyllite, silica, and diatomaceous earth.The filler generally comprises from about 1% to about 95% of the weightof the DCF based on the total wet weight of the formulation (i.e.including water). Another ingredient usually present in DCF is a binderor resin. Suitable binders include polyvinyl acetate, polyvinyl alcohol,ethylene vinyl acetate co-polymer, vinylacrylic co-polymer,styrenebutadiene, polyacrylamide, other acrylic polymers, other latexemulsions, natural and synthetic starch, and casein. These binders canbe used alone or in combination with one another. The amount of bindercan range from about 1% to about 45% of the DCF total wet weight. Morepreferably, the binder comprises from about 1% to about 20% of the totalwet weight, and most preferably, from about 4% to about 14%.

A surfactant can also be included in the DCF formulation. The surfactantgenerally comprises less than about 3.5% of the DCF total wet weight,and preferably less than about 0.25%.

Many DCF formulations also contain a cellulosic thickener, usually acellulosic ether. Suitable thickeners include methyl cellulose,hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxyethylcellulose, hydroxyethyl methyl cellulose, hydroxyethyl hydroxypropylcellulose, ethylhydroxyethyl cellulose, and sodium carboxymethylcellulose (CMC). These thickeners can be used alone or in combinationwith one another. The amount of cellulosic thickener can range fromabout 0.1% to about 2% by weight of the DCF. A preferred thickener ishydroxypropyl methyl cellulose available from Dow Chemical Company underthe trade designation Methocel.

Another ingredient that can be included in the DCF of the invention is anon-leveling agent. Suitable non-leveling agents include clays such asattapulgus clay, bentonite, illite, kaolin and sepiolite, and claysmixed with starches. Thickeners, such as those described above, can alsofunction as non-leveling agents.

Additional ingredients which can be utilized in the DCF arepreservatives, fungicides, anti-freeze wetting agents, defoamers,flocculants, such as polyacrylamide resin, and plasticizers, such asdipropylene glycol dibenzoate.

In some embodiments, perlite can be used in a DCF to, for example,control the density, shrinkage, and crack resistance of the DCF. In someembodiments, perlite need not be used (e.g., where weight is not as muchof a factor).

In some embodiments, clay can be used in a DCF as, for example, anon-leveling agent and/or a thickening agent that can control theviscosity or rheology of the final product. Clay can also help enhanceor create the water-holding properties of the DCF.

In some embodiments, thickeners can be used to control the viscosity,affect the rheology, and affect the water holding characteristics of aDCF. For example, cellulose ether can be used as a thickener.

In some embodiments, binders can be used in a DCF to, for example,improve bonding to the substrate such as coal.

In some embodiments, a glycol can be used in a DCF to provide functionalsuch as wet edge, open time, controlling drying time, and freeze/thawstability.

In some embodiments, other rheology modifiers can also be used inconjunction with, or instead of, some of the above describedcompositions.

In some embodiments, fillers can be used in the DCF although a lowerviscosity closer to that of water (for spraying purposes) is preferred.For example, calcium carbonate, calcium sulfate hemihydrates, or calciumsulfate dehydrated can all be used as fillers, though other materialscan be used as well. Further, thickeners, preservatives, binders, andother additives can be incorporated into the DCF.

Other additives can also be added to the described DCF in addition tothe asphalt emulsion. In some embodiments, metal siliconate salts suchas, for example, potassium siliconate, as well as silicone basedcompounds such as, for example, poly hydrogen methyl siloxane andpolydimethyl siloxane, could provide advantageous water resistance to aDCF. In some embodiments, fluorinated compounds and stearate-based saltscould also be used to provide advantageous water resistance.

Embodiments of the DCF can be applied in thin layers to a surface. TheDCF can be applied by, for example, using a spraying device. However,the application and thickness of the layers of DCF is not limiting.Further, multiple layers may be applied in order to obtain anappropriate dust control. The number or layers applied is not limiting.In some embodiments, each layer can be allowed to dry prior toapplication of the next layer. In some embodiments, a second layer canbe applied when the first layer is only partially dried.

In some embodiments, the DCF can be aqueous. In addition to a latexbinder, other water soluble binders, such as polyvinyl alcohol, can beused as well. Other materials, such as talc, binders, fillers,thickening agents, preservatives, limestone, perlite, urea, defoamingagents, gypsum latex, glycol, and humectants can be incorporated intothe DCF as well or can substitute for certain ingredients (e.g., talccan be used in place of, or in addition to mica; gypsum can be used inplace of, or in addition to calcium carbonate, etc.). In someembodiments, the calcium carbonate can be replaced either wholly orpartially with a surface micro-roughened filler that can further enhancethe DCF's hydrophobicity. In some embodiments, Calcimatt™, manufacturedby Omya AG, can be used. In some embodiments, cristobalite (silicondioxide) such as Sibelite® M3000, manufactured by Quarzwekre, can beused. These fillers can be used alone or in combination.

In some embodiments, the DCF is aqueous and can be applied to thesubstrate and can be allowed to dry. Once the water evaporates from themixture, a dry, relatively hard cementitious material can remain.

Table 1 describes a coal dedusting formulation which is made as 4%solution and sprayed on to coal railcars.

TABLE 1 Asphalt Emulsion Density Volume Weight Dosage Content(lbs/gallon) (Gallons) (lbs) (Wt. %) Defoamer 4.9 0.0001 Low CVS 8.42690 22,596 48 Emulsifier Asphalt Blend 7.85 3179 24,955 52 Total 47,556100

Table 2 described the CVS emulsifier that is a component of the asphaltemulsion.

TABLE 2 Low CVS Emulsifier Density Volume Weight Dosage Content(lbs/gallon) (Gallons) (lbs) (Wt. %) Water 8.34 1403 11,701 60Tetrasodium 171 0.01 pyrophosphate Vinsol solution 8.73 400 3492 17.5Defoamer 7.68 3.93 30 0.003 Clay slurry 8.69 501 4354 22.5 Potassium12.18 0.5 6 0.0002 hydroxide Total 19754.0 100

Table 3 describes the clay slurry, a component in the CVS emulsifier

TABLE 3 Clay Slurry Density Volume Weight Dosage Content (lbs/gallon)(Gallons) (lbs) (wt.) Water 8.34 1120 9341 89.4 Bentonite clay 1000 9.6Potassium oxalate 107 1 Total 10,447.8 100

Similarly, Table 4 describes an alternative formulation of the asphaltemulsion that can be used for coal dedusting.

TABLE 4 Alternative embodiment of asphalt emulsion Content Weight %Water 48.5 Asphalt blend 38.73 Bentonite clay 4.15 Phosphoric acid 0.05Preservative 0.1 Wollastonite 0.36 Kaolin clay 8 Total 100

Suitable bases include any compound that is capable of saponifying theester carboxylate group, or deprotonating the carboxylic acid proton.Suitable bases are inorganic basis such as potassium hydroxide andammonium hydroxide. Likewise, suitable organic basis are monoethanolamine, diethanol amine, ad triethanol amine.

In some embodiments, the DCF can provide water repellency. Oneindication of water repellency is the contact angle of a water dropleton the surface of the dried DCF. A water droplet surface that has acontact angle of less than 90 degrees would generally be consideredhydrophilic (the smaller the contact angle the greater thehydrophilicity). Conversely, surfaces that cause a water droplet to havea contact angle greater than 90 degrees are generally consideredhydrophobic. Commercially available ready mix DCF have contact angles ofabout zero degrees, meaning that a drop of water placed on such asurface will rapidly spread and wet out on the surface. Embodiments ofthe disclosed DCF can have a contact angle greater than about 60, 70,80, 90, 100, 110, 120, or 130. In some embodiments, the DCF can have acontact angle between about 60 and 130, about 115 and 130, or about118-120. Embodiments of the disclosed DCF, containing an asphaltemulsion, can have an average contact angle of about 98 degrees (basedon an average of six measurements), or greater than about 98 degrees,indicating a hydrophobic surface.

In some embodiments, the contact angle can be between about 60 to about110 degrees, or about 60, about 70, about 80, about 90, about 100, orabout 110 degrees.

In some embodiments, the contact angel can be any number selected fromthe following numbers in degrees:

60, 61, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78,79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96,97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111,112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125,126, 127, 128, 129, and 130.

From the foregoing description, it will be appreciated that inventivedevices and approaches for low-dust/water resistant products and asphaltemulsions have been disclosed. While several components, techniques andaspects have been described with a certain degree of particularity, itis manifest that many changes can be made in the specific designs,constructions and methodology herein above described without departingfrom the spirit and scope of this disclosure.

Certain features that are described in this disclosure in the context ofseparate implementations can also be implemented in combination as wellas in a single implementation. Conversely, various features that aredescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations, one or more features from a claimedcombination can, in some cases, be excised from the combination, and thecombination may be claimed as any subcombination or variation of anysubcombination.

Moreover, while methods may be depicted in the Drawings or described inthe specification in a particular order, such methods need not beperformed in the particular order shown or in sequential order, and thatall methods need not be performed, to achieve desirable results. Othermethods that are not depicted or described can be incorporated in theexample methods and processes. For example, one or more additionalmethods can be performed before, after, simultaneously, or between anyof the described methods. Further, the methods may be rearranged orreordered in other implementations. Also, the separation of varioussystem components in the implementations described above should not beunderstood as requiring such separation in all implementations, and itshould be understood that the described components and systems cangenerally be integrated together in a single product or packaged intomultiple products. Additionally, other implementations are within thescope of this disclosure.

Conditional language, such as “can,” “could,” “might,” or “may,” unlessspecifically stated otherwise, or otherwise understood within thecontext as used, is generally intended to convey that certainembodiments include or do not include certain features, elements, and/orsteps. Thus, such conditional language is not generally intended toimply that features, elements, and/or steps are in any way required forone or more embodiments.

Conjunctive language such as the phrase “at least one of X, Y, and Z,”unless specifically stated otherwise, is otherwise understood with thecontext as used in general to convey that an item, term, etc. may beeither X, Y, or Z. Thus, such conjunctive language is not generallyintended to imply that certain embodiments require the presence of atleast one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,”“about,” “generally,” and “substantially” as used herein represent avalue, amount, or characteristic close to the stated value, amount, orcharacteristic that still performs a desired function or achieves adesired result. For example, the terms “approximately”, “about”,“generally,” and “substantially” may refer to an amount that is withinless than or equal to 10% of, within less than or equal to 5% of, withinless than or equal to 1% of, within less than or equal to 0.1% of, andwithin less than or equal to 0.01% of the stated amount.

Some embodiments have been described in connection with the accompanyingDrawings. The figures are drawn to scale, but such scale should not belimiting, since dimensions and proportions other than what are shown arecontemplated and are within the scope of the disclosed inventions.Distances, angles, etc. are merely illustrative and do not necessarilybear an exact relationship to actual dimensions and layout of thedevices illustrated. Components can be added, removed, and/orrearranged. Further, the disclosure herein of any particular feature,aspect, method, property, characteristic, quality, attribute, element,or the like in connection with various embodiments can be used in allother embodiments set forth herein. Additionally, it will be recognizedthat any methods described herein may be practiced using any devicesuitable for performing the recited steps.

While a number of embodiments and variations thereof have been describedin detail, other modifications and methods of using and medicalapplications for the same will be apparent to those of skill in the art.Accordingly, it should be understood that various applications,modifications, materials, and substitutions can be made of equivalentswithout departing from the unique and inventive disclosure herein or thescope of the claims.

What is claimed:
 1. A dust control formulation (DCF) comprising a dustreduction additive (DRA) emulsion, said DRA emulsion comprising: (i)asphalt, (ii) at least one first defoamer, and (iii) at least oneemulsifier, wherein said at least one emulsifier is a low-fatty acidemulsifier, comprising: (a) a first water, (b) a fatty acid solution,(c) a first base, and (d) a stabilizer.
 2. The dust control formulationas recited in claim 1, further comprising a second water.
 3. The dustcontrol formulation as recited in claim 1, wherein said dust-reductionadditive emulsion further comprises a third water; a second base; and adispersant.
 4. The dust control formulation as recited in claim 1;wherein said asphalt in said DRA is from about 30% to about 70% byweight of the DRA; and/or wherein said at least one first defoamer insaid DRA is from about 0.00005% to about 0.00030% by weight of the DRA;and/or wherein said at least one emulsifier in said DRA is from about30% to about 70% by weight of the DRA.
 5. The dust control formulationas recited in claim 1, wherein said asphalt in said DRA is an asphaltblend.
 6. The dust control formulation as recited in claim 1, whereinthe stabilizer of the DRA includes ethylene-vinyl acetate-vinyl alcoholterpolymer.
 7. The dust control formulation as recited in claim 1,wherein the DRA further comprises at least one of a second defoamer anda suspension agent.
 8. The dust control formulation as recited in claim7, wherein said suspension agent is a clay slurry.
 9. The dust controlformulation as recited in claim 1, wherein said low fatty acidemulsifier comprises at least one of tetrasodium pyrophosphate, abieticacid, clay slurry, potassium hydroxide, and a second defoamer.
 10. Thedust control formulation as recited in claim 9, wherein said clay slurrycomprises bentonite clay and potassium oxalate.
 11. The dust controlformulation as recited in claim 1, wherein said dust reduction additivecomprises, asphalt blend, bentonite clay, and kaolin clay.
 12. The dustcontrol formulation as recited in claim 1, wherein the first base or thesecond base comprise: (a) at least one alkali metal hydroxide, whereinsaid at least one alkali metal hydroxide is selected from potassiumhydroxide, sodium hydroxide, lithium hydroxide, and combination thereof;(b) at least one metallic hydroxide, wherein said at least one metallichydroxide is selected from aluminum hydroxide, barium hydroxide, calciumhydroxide, magnesium hydroxide, zinc hydroxide, and combinationsthereof; and/or (c) at least one non-metallic base, wherein said atleast one non-metallic base is selected from an ammonia derivative, anamine derivative, ammonium hydroxide, and combinations thereof.
 13. Thedust control formulation as recited in claim 1, wherein said DCF furthercomprises at least one of a binder; a preservative; a rheology modifier;a surfactant; a filler; a cellulosic thickener; a preservative, afungicide; a biocide; an insecticide; an anti-freeze wetting agents; aflocculant; and a flame retardant.
 14. The dust control formulation asrecited in claim 1, comprising at least one of calcium carbonate,calcium sulfate dihydrate, calcium sulfate hemihydrates, glass microbubbles, mica, perlite, urea, talc, limestone, pyrophyllite, silica,surface micro-roughened filler, glycol, humectant, diatomaceous earth,polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate co-polymer,vinylacrylic co-polymer, styrenebutadiene, polyacrylamide, acrylicpolymer, latex emulsions, natural starch, synthetic starch, casein,methyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxyethyl methyl cellulose,hydroxyethyl hydroxypropyl cellulose, ethyl hydroxyethyl cellulose, andsodium carboxymethyl cellulose, attapulgus clay, bentonite, illite,kaolin, sepiolite, and dipropylene glycol dibenzoate.
 15. The dustcontrol formulation as recited in claim 1, wherein the pH of saidformulation is below
 9. 16. The dust control formulation as recited inclaim 1, wherein the contact angle of the dust control formulation isabout 60 to about 130 degrees.
 17. The dust control formulation asrecited in claim 1, wherein the weight of said dust reduction additiveemulsion is in the range of from about 0.01% to about 20% by weight ofsaid dust control formulation.
 18. The dust control formulation asrecited in claim 1, wherein the weight of said dust reduction additiveemulsion is in the range of from about 0.1% to about 10% by weight ofsaid dust control formulation.
 19. The dust control formulation asrecited in claim 1, wherein said dust control formulation is applied tothe surface of said bulk material at the rate of from about 0.001 toabout 5.0 gallon per square yard for controlling dust.
 20. A bulkmaterial selected from coal, limestone, fly ash, cement, carbon black,coke, or mineral material, wherein said bulk material is covered with adust control formulation comprising a dust reduction additive (DRA)emulsion, said DRA emulsion comprising: (i) asphalt, (ii) at least onefirst defoamer, and (iii) at least one emulsifier, wherein said at leastone emulsifier is a low-fatty acid emulsifier, comprising: (a) a firstwater, (b) a fatty acid solution, (c) a base, and (d) a stabilizer. 21.The bulk material as recited in claim 20, wherein the particle size ofthe bulk material being treated ranges from about 0.01 μm to about 1000μm.
 22. The bulk material as recited in claim 21, wherein said bulkmaterial is coal in an open-topped, coal-hopper railcar, used fortransporting coal.